Single use applicator

ABSTRACT

A single-use applicator for amorphous substances comprising a base panel impermeable to the amorphous substance, a frame secured to the base panel, an amorphous substance deposited about the frame, and a thin, flexible cover that is unaffected by the amorphous substance and secured to the base panel to seal the amorphous substance layer in an enclosed space.

CROSS-REFERENCES TO RELATED APPLICATIONS

The present application is a continuation-in-part application ofapplication Ser. No. 11/300,389, filed Dec. 14, 2005 for SINGLE USEAPPLICATOR in the names of Nicholas Powley and Tara Einis.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to product applicators, more specifically,to applicators for greasy and/or powdered solids and amorphoussubstances such as deodorants, antiperspirants, lotions, lubricants,skin care cosmetics, medications, ointments, suntan lotions, and paints.

2. Description of the Related Art

The purpose of an applicator is to provide a user with a method forapplying a specific and/or limited amount of a substance that isdifficult or messy to handle, or that requires special packaging.Deodorants and antiperspirants, creams, lotions, lubricants, and skincare medications are examples of the former and a two-part epoxy is anexample of the later. Current applicators are typically made withoutregard to portability, disposability, and single-use application. Theserelatively large storage containers/applicators are inconvenient forpeople needing to travel with the applicator or only requiring a limitedamount of the substance on a single occasion. Existing single-useapplicators are expensive to manufacture and often contain moving parts.Some currently available single-use packages for these substances workwell for portability, but lack a tidy means for substance application.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a portable, disposable,single-use applicator for amorphous substances and the like.

The single-use applicator of the present invention has a layer ofretentive material bonded to one side of a base panel. The retentivematerial is suffused with an amorphous substance and sealing under acover. The applicator is intended for use with creams, gels, powders,and other amorphous substances.

The area of the base panel to which the retentive material is adhered isimpervious to the substance. The percentage of the base panel that holdsthe substance can be any proportion of the overall panel. Preferredmaterials include synthetic resin films and metal foils. Optionally, thebase panel includes a handle that projects out from the base panel.Optionally, the base panel includes textured surfaces and/or imprintedgraphics, words, or logos.

The retentive layer is composed of a porous material that can retain thesubstance without substantial product loss, but expels the substancewhen used in its intended manner. The retentive layer material dependson the substance and holds enough for at least one use. The method forbonding the retentive material to the base panel depends upon thematerials and is accomplished by well-known adhesive techniques.

Semi-solid substances can be applied to the base panel using a tray orframe. The tray or frame is attached to the base panel. The substance isdeposited into the tray or about the frame.

After the retentive layer is suffused with the substance, it is sealedwith a removable cover. The cover is preferably composed of a foil ofmetal such as an aluminum alloy, a plastic, a laminate of metal andplastic, paper, or recycled materials. The adhesive is strong enough tomaintain a hermetic seal, but weak enough so that the cover can bemanually peeled from the base panel. Optionally, the base panel andcover are a single sheet and the cover is delimited by folding the sheetover.

Optionally, the applicator is supplied with a removable adhesive on itsouter surface to attach it to another package.

Other objects of the present invention will become apparent in light ofthe following drawings and detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and object of the presentinvention, reference is made to the accompanying drawings, wherein:

FIG. 1 is an exploded view of one embodiment of the applicator of thepresent invention;

FIG. 2 is an exploded view of a second embodiment of the applicator ofthe present invention;

FIG. 3 is a cross-sectional view of the applicator of FIG. 1 taken alongthe line 3-3;

FIG. 4 is a cross-sectional view of an alternate method to applysemi-solid substances to the base;

FIG. 5 is a cross-sectional view of an second alternate method to applysemi-solid substances to the base;

FIG. 6 is a bottom view of the application method of FIG. 5;

FIG. 7 is an exploded view of a third embodiment of the applicator ofthe present invention;

FIG. 8 is an exploded view of a fourth embodiment of the applicator ofthe present invention;

FIG. 9 is a cross-sectional view of the applicator of FIG. 8 taken alongthe line 9-9;

FIG. 10 is an assembled view of a fifth embodiment of the applicator ofthe present invention;

FIG. 11 is an exploded view of one configuration of the applicator ofFIG. 10;

FIG. 12 is an exploded view of another configuration of the applicatorof FIG. 10;

FIG. 13 is an exploded view of another configuration of the applicatorof FIG. 10;

FIG. 14 is an exploded view of another configuration of the applicatorof FIG. 10;

FIG. 15 is a cross-sectional view of the applicator of FIG. 10 takenalong the line 15-15; and

FIG. 16 is an exploded view of the applicator of the present inventionadhered to another package.

DETAILED DESCRIPTION OF THE INVENTION

The single use applicator 10 of the present invention is constructed bybonding a layer of retentive material 14 to one side of a base panel 12,suffusing the retentive material 14 with an amorphous substance 30, andsealing the retentive material 14 under a cover 16 so that the substance30 remains in the retentive material 14 and free from contamination.Alternatively, the amorphous substance 30 is applied directly to oneside of the base panel 12. The applicator 10 is intended for use withcreams, gels, powders, and other amorphous substances.

The base panel 12 is a sheet composed of materials that are flexible,semi-rigid, or rigid. The area 26 to which the retentive material 14 isadhered is non-porous, not wettable by water, and is insoluble in waterand the substance 30.

Typical flexible, impermeable sheets are synthetic resin films. Theseresin films include polyolefins and polyvinyl copolymers, such aspolyethylene, polypropylene, polybutylene, polyvinyl acetate, polyvinylchloride, polyvinylchloride-vinylidene chloride and the like. Thechlorinated polyvinyl copolymers are highly resistant to degradationcaused by exposure to either water- or alcohol-based fluids. The basepanel 12 may also be composed of metal foils such as an aluminum alloy,a plastic, or a laminate of metal and plastic. A base panel 12 made fromthese materials is flexible, has strength characteristics sufficient toresist tearing and piercing under normal manufacturing and handlingstresses, is nonwettable by water, and can be sterilized and colored.The preferred thickness of the base panel 12 is from about 0.5 mils toabout 80 mils.

Optionally, the base panel 12 extends beyond the retentive materialattachment area 26 to form a handle 28. Optionally, the handle 28 and/orthe surface 20 of the base panel 12 opposite that of the retentive layer14 may include textured surfaces, grips extending from the surface,and/or imprinted graphics, words, or logos.

The retentive layer 14 is composed of a porous material, such as gauzecotton, prepared cotton, other organic fibers such as wood fibers,rayon, open-meshed cloth of varying degrees of fineness, woven andnon-woven synthetic fibers, and foamed polymers such as polyurethane.These materials maintain their integrity when moistened. The retentivelayer 14 is sufficiently retentive to store and apply a useable amountof substance 30. The retentive layer 14 is able to contain the substance30 without extensive or substantial product loss (i.e., dripping), butexpels the substance 30 when the proper pressure is applied or used inits intended manner.

Typically, the thickness of the retentive layer 14 depends upon thematerial and surface area of the applicator 10. Different materials areused appropriately for the application of various substances 30. Theretentive layer 14 holds enough substance 30 for at least oneuse/application. The actual amount that the retentive layer 14 holdsdepends upon the substance 30 and the amount necessary to perform itsfunction adequately, and will typically be in 1 to 10 ml range. Forexample, when the substance 30 is a deodorant, the retentive layer 14will be able to hold 1 to 10 ml of the deodorant.

The method for bonding the retentive material 14 to the base panel 12depends upon the materials of which the base panel 12 and retentivelayer 14 are made, and is accomplished by standard techniques well-knownin the art of adhesives. The bond is resistant to degradation caused byexposure to the substance 30. To achieve a good bond, it is a commonpractice to first degrease or rinse the retentive layer surface 18 ofthe base panel 12 by an organic solvent such as acetone or methyl ethylacetone. Degreasing prepares the surface 18 for bonding.

Because the preferred retentive materials are porous, capable ofabsorbing liquefied polymers, and allow the evaporation of vapor, mostof the standard joining methods using adhesives with or without solventscan be used. A preferred method for joining the base panel 12 to theretentive layer 14 is to apply a thin coat of a molten polyolefin, suchas polyethylene, polypropylene, or polybutylene, onto the retentivelayer surface 18 by extrusion, apply the retentive layer 14 contiguouslyto the retentive layer surface 18, and press them together before thecoat solidifies. Alternatively, instead of applying a thin coat ofpolyolefin by extrusion, the standard rolling technique of directgravure can be used to print the thin coat to selected areas of theretentive layer surface 18. Optionally, the retentive layer 14 isprecoated with a polymer. The molten polyolefin absorbed into theretentive layer 14 will anchor to the base panel 12 and, when cooled,will bind the retentive layer 14 and the base panel 12 together.

Alternatively, the retentive layer 14 is joined to the base panel 12 byapplying a solid powder polyolefin to the retentive layer surface 18 ofthe base panel 12, placing the retentive layer 14 on top of the powder,and subjecting the two to a high-pressure heat seal.

Alternatively, as shown in FIG. 2, the substance 30 applied directly tothe base panel 12. Texturing on the base panel 12 or other supplementarygeometries may assist in the fixation of the substance 30 to the basepanel 12. Optionally, the substance may be adhered in series of shapesincluding, but not limited to, rows, dots, letters and numbers, andsymbols.

Semi-solid substances, such as wipe-on deodorants, can be applied to thebase panel 12 using a tray 32, as shown in FIG. 4. The tray 32 is a low,plastic tray into which the substance 30 is deposited. Then the tray 32is adhered to the base panel 12 by using any adequate method known inthe art, including adhesives, epoxies, and ultrasonic welds, as well asthe methods described above with reference to the retentive layer 14.Alternatively, the tray 32 is adhered to the base panel 12 and then thesubstance 30 is deposited in the tray 32.

Semi-solid substances can be also applied to the base panel 12 using aframe 34, as shown in FIGS. 5 and 6. The frame 34 is a thin, plasticshape, such as the cross shown in FIG. 6, around which the substance 30is deposited. The frame 34 becomes embedded in the bottom of thesubstance 30. Then the frame 34 is adhered to the base panel 12.Alternatively, the frame 34 is adhered to the base panel 12 and then thesubstance 30 is deposited around the frame 34.

After the retentive layer 14 is suffused with the substance 30, it issealed into an enclosed space 22 between the base panel 12 and aremovable cover 16. The space 22 is hermetic so that the retentive layer14 remains moist and uncontaminated by external agents. The space 22remains hermetic for an extended period of time that represents theshelf life of the applicator 10, which includes the period of time fromthe installation of the cover 16, through transportation and storage, touse, when the cover 16 is removed. The cover 16 can be large or smallenough to cover the base panel 12 in its entirety or any portionthereof.

The cover 16 is a planar sheet that is preferably composed of a foil ofmetal such as an aluminum alloy, a plastic, or a laminate of metal andplastic. Alternatively, the cover 16 can be composed of paper orrecycled materials, and/or can be coated. The cover 16 is robust enoughto maintain integrity while being subjected to normal stressesthroughout transportation, storage, and handling. The cover 16 isunaffected by water and the substance 30 during the shelf life of theapplicator 10.

The adhesive used to adhere the cover 16 to the base panel 12 is strongenough to maintain the hermetic seal, but weak enough so that a smallamount of tensional stress, such as that caused by manually peeling thecover 16 from the base panel 12, will cause the adhesive to fracture,allowing the cover 16 to be separated from the base panel 12. Theadhesive is unaffected by water and the substance 30 during the shelflife of the applicator 10. Adhesive materials include urethanes andpolyurethanes.

The embodiment 80 of FIG. 7 can be used with substances that would stickto the cover during removal. The substance 86 is positioned in a capsule88 between the base panel 82 and a capsule cover 84. The peripheral seam94 between the base panel 82 and capsule cover 84 has a weakened section90 adjacent to an application region 92 of the base panel 82. Prior toapplication, the capsule 88 is pressed so that the substance 84 rupturesthe weakened section 90 and squeezes onto an application region 92.

The embodiment of FIGS. 8 and 9 can be used when there is more than onesubstance 62, 64. The substances 62, 64 are separated by positioningthem in the space between the base panel 52 and a capsule cover 66. Thecapsule cover 66 is adhered to the base panel 52 around the edge and ata line between the substances 62, 64, as at 72, creating two capsules68, 70 to house the substances 62, 64. Prior to application, the twocapsules 68, 70 are pressed so that the two substances 62, 64 aresqueezed through a weakened area 76 of the cover/base panel seam andonto the mixing area 60 under the cover 56. The substances 62, 64 aremixed together by massaging the mixing area with the fingers on thecover 56 and base panel 52. Alternatively, the substances 62, 64 aremixed after removing the cover 56 by using an optional wand 74 that isremovably attached to the base panel 52. Alternatively, the substances62, 64 are mixed using the cover 56 after it is removed. Optionally, thecover 56 and the capsule cover 66 are a single sheet.

The embodiment of FIGS. 10-15 does not have a separate cover. Rather,the cover 106 is an extension of the base panel 102. In theconfiguration of FIG. 11, the substance 30 is applied by use of aretentive layer 104 attached to the base panel 102 at a retentive layerattachment area 116, as described above with reference to FIG. 1. Theretentive layer 104 can extend over both the base panel 102 and cover,as shown in FIG. 11, or over only one of them, as in FIGS. 12 and 13. Inthe configuration of FIG. 14, the substance 30 is applied directly tothe base/cover, as described with reference to FIG. 2. The substance 30can be applied to both the base panel 102 and cover 106, as shown inFIG. 14, or to only one of them, similar to FIGS. 12 and 13. After thesubstance 30 is applied, the cover 106 is folded over the base panel 102at a fold line 108 and sealed to the base panel 102 as described above.

The present invention contemplates that the applicator 10 may beremovably adhered to other packages, as shown in FIG. 16. Examples ofsuch use are as a sample of the product inside the package or as asample of a complementary product. The rear of the applicator 10 has anadhesive 42 that attaches the applicator 10 to a package 40, as at 44.The particular adhesive 42 used depends upon the material of the package40 and should securely adhere the applicator 10 to the package 40, butallow for relatively easy removal. Typically, an acrylic adhesive hasthe desired combination of security and removability.

Optionally, the adhesive may be re-sealable to enable multiple uses ofthe applicator 10. Resealable adhesives materials include acrylics.

Optionally, the cover 16 is vacuum-sealed to alleviate the need forstrong adhesives that would prevent easy removal of the cover.

Optionally, as shown in FIGS. 1 and 10, there is a finger tab 24, 110extending from one edge of the cover 16, 106 that can be grasped betweena thumb and finger for ease and convenience in removing the cover 16,106 from the base panel 12, 102.

Optionally, the cover 16 may include textured surfaces and/or imprintedgraphics, words, or logos. The printed graphics may include postage.

Optionally, the applicator 10 is encased in a foil or plastic pouch forincreased protection, marketing/product design, and/or ease oftransportation.

Optionally, the applicator 10 is tessellated for ease of manufacturingand distribution.

Thus it has been shown and described an applicator which satisfies theobjects set forth above.

Since certain changes may be made in the present disclosure withoutdeparting from the scope of the present invention, it is intended thatall matter described in the foregoing specification and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense.

1. An applicator for an amorphous substance comprising: (a) a base panelthat is impermeable to said amorphous substance; (b) a frame attached tosaid base panel; (c) said amorphous substance deposited on said frame;(d) a cover composed of a thin, flexible sheet that is unaffected bysaid amorphous substance; (e) a cover securing means for securing saidcover to said base panel such that said frame and amorphous substanceare enclosed in a closed space between said base panel and said cover,said cover securing means having a tensional stress resistance thatpermits manual removable of said cover from said base panel.
 2. Theapplicator of claim 1 wherein said frame is embedded within saidamorphous substance.
 3. The applicator of claim 1 wherein said frame isa thin plastic.
 4. The applicator of claim 1 wherein said base panelincludes a handle.
 5. The applicator of claim 1 wherein said base paneland cover are comprised of a single, contiguous sheet.
 6. The applicatorof claim 1 wherein said cover includes a finger tab to facilitateremoval.
 7. The applicator of claim 1 wherein said base panel and/orsaid cover is adapted to receive graphics.
 8. The applicator of claim 1wherein said base panel and/or cover is textured.
 9. An applicator foran amorphous substance comprising: (a) a base panel that is impermeableto said amorphous substance, said base panel having a handle; (b) athin, plastic frame attached to said base panel; (c) said amorphoussubstance deposited about said frame such that said frame is embedded insaid substance; (d) a cover composed of a thin, flexible sheet that isunaffected by said amorphous substance, said cover having a finger tabto facilitate removal; (e) a cover securing means for securing saidcover to said base panel such that said frame and amorphous substanceare enclosed in a closed space between said base panel and said cover,said cover securing means having a tensional stress resistance thatpermits manual removable of said cover from said base panel.
 10. Theapplicator of claim 9 wherein said base panel and cover are comprised ofa single, contiguous sheet.
 11. The applicator of claim 9 wherein saidbase panel and/or said cover is adapted to receive graphics.
 12. Theapplicator of claim 9 wherein said base panel and/or cover is textured.13. A method of producing an applicator for an amorphous substancecomprising the steps of: (a) providing a base panel that is impermeableto said amorphous substance; (b) attached a frame to said base panel;(c) depositing said amorphous substance on said frame; (d) securing acover that is composed of a thin, flexible sheet that is unaffected bysaid amorphous substance to said base panel such that said frame andamorphous substance is contained within a closed space between said basepanel and said cover, said cover securing means having a tensionalstress resistance that permits manual removable of said cover from saidbase panel.
 14. The method of claim 13 wherein said amorphous substanceis deposited about said frame such that said frame is embedded withinsaid amorphous substance.
 15. The method of claim 13 wherein said frameis a thin plastic.
 16. The method of claim 13 wherein said base panel isprovided with a handle.
 17. The method of claim 13 wherein said basepanel and cover are comprised of a single, contiguous sheet.
 18. Themethod of claim 13 wherein said cover is provided with a finger tab tofacilitate removal.
 19. The method of claim 13 further comprisingimprinting graphics on said base panel and/or said cover.
 20. The methodof claim 13 further comprising texturing said base panel and/or saidcover.